Auxiliary Climate Control: Removal & Installation Ford Explorer V

Removal

1. Remove the LH quarter trim panel. For additional information, REFER to «QUARTER TRIM PANEL - WITH INFLATABLE SAFETY BELTS»(ref-517611-S17767228592012121200000) or «QUARTER TRIM PANEL - WITHOUT INFLATABLE SAFETY BELTS»(ref-517611-S06410098392012121200000) .
2. Disconnect the auxiliary blower motor electrical connector.
3. Detach the 2 auxiliary wire harness clips from the auxiliary heater core and evaporator core housing and position the wire harness away from the blower motor.
4. Remove the 3 auxiliary blower motor screws.
5. Remove the auxiliary blower motor.

Installation

1. To install, reverse the removal procedure.

Scheme 11

Scheme 12

1. Remove the LH quarter trim panel. For additional information, REFER to «QUARTER TRIM PANEL - WITH INFLATABLE SAFETY BELTS»(ref-517611-S17767228592012121200000) or «QUARTER TRIM PANEL - WITHOUT INFLATABLE SAFETY BELTS»(ref-517611-S06410098392012121200000) .
2. Detach the auxiliary blower motor speed control. Gently depress the auxiliary blower motor speed control retaining tab. With the retaining tab depressed, slide the auxiliary blower motor speed control toward the front of the vehicle to detach it from the auxiliary climate control housing. Remove the auxiliary blower motor speed control.
3. Disconnect the auxiliary blower motor speed control electrical connector.

1. To install, reverse the removal procedure.

Scheme 13

1. Detach the 4 floor console rear trim panel clips and remove the floor console rear trim panel. Disconnect the electrical connectors.
2. Remove the 4 auxiliary climate control assembly screws.
3. Disconnect the auxiliary climate control assembly electrical connector and remove the auxiliary climate control assembly.

1. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Drain the engine cooling system. For additional information, REFER to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.0L GTDI»(ref-517561-S31925988682012121200000) or «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT»(ref-517561-S41303553832012121200000) .
3. Recover the refrigerant. For additional information, REFER to «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING - DATC»(ref-517581-S30981876462012121200000) or «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION AND CHARGING - EMTC»(ref-517582-S39162093072012121200000) .
4. Remove the LH c-pillar trim panel. For additional information, REFER to «C-PILLAR TRIM PANEL - WITH INFLATABLE SAFETY BELTS»(ref-517611-S35254511472012121200000) or «C-PILLAR TRIM PANEL - WITHOUT INFLATABLE SAFETY BELTS»(ref-517611-S29416342532012121200000) .
5. Remove the auxiliary evaporator line fitting nuts at the floorpan connection and disconnect the fittings. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (133 lb-in).
6. Release auxiliary heater line clamps and disconnect the auxiliary heater outlet and inlet lines at the auxiliary floorpan bracket.
7. Remove the 2 auxiliary line floorpan bracket nuts. To install, tighten to 9 Nm (80 lb-in).
8. Disconnect the auxiliary climate control housing electrical connector.
9. Remove the auxiliary floor duct pin-type retainer and the auxiliary floor duct.
10. Remove the 3 auxiliary climate control housing bolts. To install, tighten to 9 Nm (80 lb-in).
11. Remove the auxiliary climate control housing.

1. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, REFER to «REFRIGERANT OIL ADDING - EMTC»(ref-517582-S30943242412012121200000) .
2. Fill the engine coolant level. For additional information, REFER to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.0L GTDI»(ref-517561-S31925988682012121200000) or «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT»(ref-517561-S41303553832012121200000) .
3. Evacuate, leak test and charge the refrigerant system. For additional information, REFER to «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING - DATC»(ref-517581-S30981876462012121200000) or «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION AND CHARGING - EMTC»(ref-517582-S39162093072012121200000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Recover the refrigerant. For additional information, REFER to «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING - DATC»(ref-517581-S30981876462012121200000) or «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION AND CHARGING - EMTC»(ref-517582-S39162093072012121200000) .
3. Drain the engine cooling system. For additional information, REFER to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.0L GTDI»(ref-517561-S31925988682012121200000) or «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT»(ref-517561-S41303553832012121200000)
4. Remove the rear subframe. For additional information, REFER to «SUBFRAME - REAR»(ref-517624-S03103494362012121200000) .
5. Remove the front auxiliary evaporator inlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
6. Remove the front auxiliary evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
7. Release the 2 front auxiliary heater line heater hose clamps and disconnect the hoses.
8. Release the 2 rear auxiliary heater hose clamps at the floorpan connection and disconnect the heater hoses.
9. Remove the rear auxiliary evaporator inlet line fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 15 Nm (133 lb-in).
10. Remove the rear auxiliary evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 15 Nm (133 lb-in).
11. Correctly support the fuel tank and remove the LH fuel tank strap bolt. To install, tighten to 35 Nm (26 lb-ft).
12. Position the LH fuel tank strap aside.
13. Remove the front and rear auxiliary line bracket nuts. To install, tighten to 5 Nm (44 lb-in).
14. Remove the 5 auxiliary line bracket bolts and remove the auxiliary evaporator and heater line bundle as an assembly. To install, tighten to 5 Nm (44 lb-in).
15. NOTE: Before detaching any of the auxiliary lines from the auxiliary line brackets, mark the position of the line(s) in relation to each bracket to make sure that the line is reinstalled in the correct position. NOTE: If only one auxiliary evaporator line is to be removed, detach only the desired line from the line brackets whenever possible. Detach the auxiliary evaporator line(s) from the auxiliary line brackets as needed.

1. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, REFER to «REFRIGERANT OIL ADDING - EMTC»(ref-517582-S30943242412012121200000) .
2. Fill the engine coolant level. For additional information, REFER to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.0L GTDI»(ref-517561-S31925988682012121200000) or «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT»(ref-517561-S41303553832012121200000)
3. Evacuate, leak test and charge the refrigerant system. For additional information, REFER to «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING - DATC»(ref-517581-S30981876462012121200000) or «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION AND CHARGING - EMTC»(ref-517582-S39162093072012121200000) .

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Remove the auxiliary climate control housing. For additional information, REFER to «Auxiliary Climate Control Housing»(ref-517583-S05757502532012121200000) .
2. Remove the 2 auxiliary temperature blend door actuator screws and position the actuator aside.
3. NOTE: The auxiliary line floorpan bracket screws are loosened only to allow the auxiliary heater core tubes to be removed. Do not fully disassemble the floorpan bracket or separate the floorpan gasket from the bracket. If the floorpan gasket is separated from the bracket, or if it is damaged, a new gasket must be installed to avoid noise and water leak concerns. Loosen the 2 auxiliary line floorpan bracket screws.
4. Remove the 2 auxiliary heater core tube clips at the heater core. Release the auxiliary heater core tube clip retaining tabs. Remove the auxiliary heater core tube clips.
5. Remove the auxiliary heater core tubes.
6. Remove the 2 screws and the auxiliary heater core access cover.
7. Remove the auxiliary heater core.

1. To install, reverse the removal procedure. Install the new O-ring seals included in the auxiliary heater core service kit.

1. NOTE: All vehicles With the vehicle in NEUTRAL, position it on a hoist. For additional information, REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Drain the engine cooling system. For additional information, REFER to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.0L GTDI»(ref-517561-S31925988682012121200000) or «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT»(ref-517561-S41303553832012121200000)
3. Recover the refrigerant. For additional information, REFER to «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING - DATC»(ref-517581-S30981876462012121200000) or «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION AND CHARGING - EMTC»(ref-517582-S39162093072012121200000) .
4. Remove the rear subframe. For additional information, REFER to «SUBFRAME - REAR»(ref-517624-S03103494362012121200000) .
5. Remove the front auxiliary evaporator inlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
6. Remove the front auxiliary evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
7. Correctly support the fuel tank and remove the LH fuel tank strap bolt. To install, tighten to 35 Nm (26 lb-ft).
8. Position the LH fuel tank strap aside.
9. Remove the front and rear auxiliary line bracket nuts. To install, tighten to 5 Nm (44 lb-in).
10. Remove the 5 auxiliary line bracket bolts and remove the auxiliary evaporator and heater line bundle as an assembly. To install, tighten to 5 Nm (44 lb-in).
11. NOTE: Before detaching any of the auxiliary lines from the auxiliary line brackets, mark the position of the line(s) in relation to each bracket to make sure that the line is reinstalled in the correct position. NOTE: If only one auxiliary heater line is to be removed, detach only the desired line from the line brackets whenever possible. Detach the auxiliary heater line(s) from the auxiliary line brackets as needed.

1. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, REFER to «REFRIGERANT OIL ADDING - EMTC»(ref-517582-S30943242412012121200000) .
2. Fill the engine coolant level. For additional information, REFER to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.0L GTDI»(ref-517561-S31925988682012121200000) or «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT»(ref-517561-S41303553832012121200000) .
3. Evacuate, leak test and charge the refrigerant system. For additional information, REFER to «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING - DATC»(ref-517581-S30981876462012121200000) or «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION AND CHARGING - EMTC»(ref-517582-S39162093072012121200000) .

Scheme 18

1. Remove the LH quarter trim panel, REFER to «QUARTER TRIM PANEL - WITH INFLATABLE SAFETY BELTS»(ref-517611-S17767228592012121200000) or «QUARTER TRIM PANEL - WITHOUT INFLATABLE SAFETY BELTS»(ref-517611-S06410098392012121200000) .
2. Remove the 2 auxiliary mode door actuator screws.
3. Disconnect the auxiliary mode door actuator electrical connector.
4. Remove the auxiliary mode door actuator.

1. To install, reverse the removal procedure.

Scheme 19

1. Remove the LH quarter trim panel, REFER to «QUARTER TRIM PANEL - WITH INFLATABLE SAFETY BELTS»(ref-517611-S17767228592012121200000) or «QUARTER TRIM PANEL - WITHOUT INFLATABLE SAFETY BELTS»(ref-517611-S06410098392012121200000) .
2. Remove the 2 auxiliary temperature blend door actuator screws.
3. Disconnect the auxiliary temperature blend door actuator electrical connector.
4. Remove the auxiliary temperature blend door actuator.

1. To install, reverse the removal procedure.

1. Recover the refrigerant. For additional information, REFER to «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING - DATC»(ref-517581-S30981876462012121200000) or «AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION AND CHARGING - EMTC»(ref-517582-S39162093072012121200000) .
2. Remove the LH quarter trim panel. For additional information, REFER to «QUARTER TRIM PANEL - WITH INFLATABLE SAFETY BELTS»(ref-517611-S17767228592012121200000) or «QUARTER TRIM PANEL - WITHOUT INFLATABLE SAFETY BELTS»(ref-517611-S06410098392012121200000) .
3. Remove the auxiliary TXV fitting nut and disconnect the fitting. Discard the O-ring seals. To install, tighten to 15 Nm (133 lb-in).
4. Remove the 2 auxiliary TXV bolts and the auxiliary TXV. Discard the O-ring seals. To install, tighten to 8 Nm (71 lb-in).

1. To install, reverse the removal procedure. Install new O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. REFER to «REFRIGERANT OIL ADDING - DATC»(ref-517581-S42144490632012121200000) .